Bulldog Hydraulic Winches Instruction Manual · 1.Disconnect power to the hydraulic pump or...

HW Series Hydraulic WinchesInstruction Manual

To prevent SERIOUS INJURY, DEATH and PROPERTY DAMAGE, you should read, understand and follow the warnings and instructions in this manual. Keep for future reference.

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2

Read, Understand, Follow and Save These Instructions

• Read,understandandfollowalloftheseinstructionsandwarningsbeforeinstallingandusingthisproduct.

• Installandusethisproductonlyasspecifiedintheseinstructions.• Improperinstallationoruseofthisproductmayresultinpropertydamage,seriousinjury,and/or

death.• Neverallowinstallationoruseofthisproductbyanyonewithoutprovidingthemwiththeseinstruc-

tions.• Youmustread,understandandfollowallinstructionsandwarningsforanyproduct(s)towhichthis

productisusedinconjunctionwithorinstalled.• Savetheseinstructionswiththeproductforuseasareferenceforanyfutureinstallationanduseof

theproduct.

Table Of ContentsSafety Page

ImportantSafetyMessages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3KnowYourWinch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4FeaturesandRatings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Instructions

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 612

. . . 15

InstallationInstructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OperationInstructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Thesafetyalertsymbolalertsyoutopotentialphysicalinjuryhazards.Obeyallsafetymessagesthatfollowthissymboltoavoidpossibleinjuryordeath.

WARNINGindicatesahazardoussituationthat,ifnotavoided,couldresultindeathorseriousinjury.

NOTICEindicatesahazardoussituationthat,ifnotavoided,couldresultinpropertydamage

CAUTIONindicatesahazardoussituationthat,ifnotavoidedcouldresultinminorormoderateinjury.

Throughout this manual WARNING, CAUTION, NOTICE and the SAFETY ALERT SYMBOL will be used.

WARNING CAUTION NOTICE

3

Before First Operation

• Purchaser/ownermustensurethatproductisinstalledac-cordingtotheseinstructions.Purchaser/ownermustnotalterormodifyproduct.

• Understandyourwinchanditsinstructions.

• Neverexceedmaximumratedcapacity.Refertostampedmarkingsordecalsonproducttoobtainratedcapacity.

• Thewinchisratedatthefirstlayerofwireropeonthedrumforcontinuousduty.

• ThewinchisratedatthefirstlayerofwireropeonthedrumforS3 10%ED & 1 min/10 min rating intermittent periodic duty.Notcontinuousduty.

Are you ready to pull?

• NEVERoperatethiswinchwhenundertheinfluenceofdrugs,alcoholormedication.

• ALWAYSremovejewel-ryandweareyeprotection.

• Useleatherglovesorahandsavercablestrapwhenhandlingthewirerope.

• NEVERletwinchropeslipthroughyourhands.

• Nevertouchawinchropeorhookwhensomeoneelseisatthecontrols.

• NEVERtouchwinchropeorhookwhileundertensionorunderload.

• ALWAYSstandclearofwinchropeandloadandkeepothersawaywhilewinching.

• Donotusethewinchasaliftingdeviceorahoistforverticallift.

• Operatorandbystandersshouldneverpositionanypart

ofbodyunderanyportionofthisproductortheloadbeingsupported.

• Donotallowchildrentoplayonoraroundthisproductortheloadbeingsupported.

• Keepclearofwinch,rope,hook,andfairleadwhileoperating.

• Thewinchisnottobeusedtolift,supportorother-wisetransportpersonnel.

• ALWAYSbeawareofpossiblehotsurfacesatwinchmotor,drumorropeduringorafterwinchuse.

• ALWAYSensuretheoperatorandbystandersareawareofthestabilityofthevehicleand/orload.

Is your winch ready to pull?

• ALWAYSinspectwinchrope,hook,andslingsbeforeop-eratingwinch.Frayed,kinkedordamagedwinchropemustbereplacedimmediately.Damagedcomponentsmustbereplacedbeforeoperation.

• Periodicallycheckmountinghardwareforpropertorqueandtightenifnecessary.

• ALWAYSremoveanyelementorobstaclethatmayinterferewithsafeoperationofthewinch.

• Wireropecanbreakwithoutwarning.Alwayskeepasafedistancefromthewinchandropewhileunderaload.

• NEVERwrapwinchropebackontoitself.Useachokerchainorstrap.

• ALWAYSensurehooklatchisclosedandnotsupport-ingload.

• NEVERapplyloadtohooktiporlatch.Applyloadonlytothecenterofhook.

• NEVERuseahookwhosethroatopeninghasincreased,orwhosetipisbentortwisted.

• ALWAYSuseahookwithalatch.

• Neverusewinchropefortowing.

• NEVERuseexcessiveefforttofreespoolwinchrope.

• ALWAYStaketimetouseap-propriateriggingtechniquesforawinchpull.

During the pull

• NEVERexceedwinchorwinchroperatedcapacity.Doublelineusingasnatchblocktoreducewinchload.

• Donotshockloadthewinch.• Neveruseawinchtosecureaload.

• ALWAYSun-spoolasmuchwinchropeaspossiblewhenrigging.Doublelineorpickdistantanchorpoint.

• Neverengageordisengagetheclutchwhenthewinchisunderloadorthedrumismoving.

• Pullfromanangleoflessthan±5degreeslaterallyand±15degreeshorizontally.Withoutmaintainingtheproperfleetan-gleof±5degrees;(SeeFigure10page14)theropewillpileontoonesideoftheropedrumandpossiblydodamagetotheropeorwinch.Re-spoolyourwinchasrequired.

• Whenwinchingaheavyload,layarecoverydamperoraheavyblanketoverthemiddlethirdofthewirerope.

• ALWAYSavoidsidepullswhichcanpileupwinchropeatoneendofthedrum.Thiscandam-agewinchropeorwinch.

• ALWAYSensuretheclutchisfullyengagedordisengaged.

• NEVERsubmergewinchinwater.

Important Safety Messages

4

Figure 1 - Winch Components

Know Your Winch

Winch Drum

Over-Center Valve

PlanetaryGear Box

ClutchT-Handle

Hydraulic Motor

Roller Fairlead(with Mounting Hardware)

Mounting Footprint Template

Hand Saver Cable Strap

Drum Drag Bolt

5

Features and Ratings

Load RatingLoadandspeedvariesaccordingtohowmuchwireropeisonthedrum.Thefirstlayerofropeonthedrumdeliverstheslowestspeedandthemaximumload.Afulldrumdeliversthemaximumspeedandtheminimumload.Forthisreason,allindustrialwinchesareratedattheirfirstlayercapacities.

Table 1 - Winch Capacity

HW8000 HW12000 HW15000Rope Layer

Capacity Length of Rope on

Drum

Rope Layer


Drum

Rope Layer


Drum

1st 8,000lbs./3,630kgs.

25.6ft./7.8m.

1st 12,000lbs./5,440kgs.

23ft./7m.

1st 15,000lbs./6,800kgs.

23.3ft./7.1m.

2nd 6,669lbs./3,025kgs.

56.1ft./17.1m.

2nd 10,075lbs./4,570kgs.

50.9ft./15.5m.

2nd 12,273lbs./5,567kgs.

51.5ft./15.7m.

3rd 5,717lbs/2,593kgs.

91.9ft./28m.

3rd 8,684lbs./3,939kgs.

82ft./25m.

3rd 10,390lbs./4,713kgs.

85ft./25.9m.

4th 5,002lbs/2,269kgs.

131ft./40m.

4th N/A N/A 4th 9,008lbs./4,086kgs.

123.4ft./37.6m.

5th N/A N/A 5th N/A N/A 5th 7,950lbs./3,606kgs.

165ft./50.3m.

Table 2 - Winch Specifications

Powered Winches

HW8000 HW12000 HW15000

Wire rope 3/8”x131’(9.5mmx30.5m)1,960N/m2EIPSGrade

Aminimumbreakingstrengthof15,663lbf./69.8kN

1/2”x82’(12.7mmx25m)1,960N/m2EIPSGrade


1/2”x165’(12.7mmx50.3m)1,960N/m2EIPSGrade


Brake Dragbrakeandover-centervalveprovidedfor100%braking.

Clutch (free- spooling)

TurnclutchbyaergonomicT-handleforrapidwireropepayout.

Table 3 - Line Speed at 15.9 g/min (60 l/min)

HW8000 HW12000 HW15000Rope Layer

Line Speed(FPM/MPM)

Rope Layer

Line Speed(FPM/MPM)

Rope Layer

Line Speed(FPM/MPM)

1st 49/15 1st 36/11 1st 30/9

2nd 59.7/18.2 2nd 43.3/13.2 2nd 35.8/10.9

3rd 69.8/21.2 3rd 51.2/15.6 3rd 42/12.8

4th 79.4/24.2 4th N/A 4th 48.6/14.6

5th N/A 5th N/A 5th 55/16.8

FPM = Feet Per Minute MPM = Meters Per Minute Based on Operation Pressure 2175 PSI / 150 Bar.

6

Mounting Hardware RequirementsEight(8)WinchMountingBoltsandtwo(2)FairleadMountingBolts,Nuts,andWashersarerequired.RefertoTable4onpage9forboltquantity,sizes,andrequiredtorque.Mountingsystemwilldictateboltlength.

ALWAYS torque mounting bolts to the values specified for your winch in Table 4 page 9 to prevent vibration during operation.ALWAYS use a grade 8 class 12.9 metric or better hardware.NEVER weld mounting bolts. ALWAYS choose the proper bolt length for your application.ALWAYS confirm required bolt length to ensure proper thread engagement.

BefORe InSTaLLIng and uSIng yOuR HydRauLIC WInCH, Read and fOLLOW aLL MOunTIng InSTRuCTIOnS and SafeTy MeSSageS.

Mounting

To prevent accidental activation of the winch and serious injury, complete the winch installation and attach the hook before installing the hydraulic lines.

1. Before Installation

WARNING

Installation Instructions

1.1 Inspect PartsHand Saver Cable Strap

Clutch T-Handle

Instruction/Owners Manual

Winch Assembly

Roller Fairlead

Mounting Footprint Template

Mounting Hardware

Drum Drag Bolt

1.2 Select Mount Location

ALWAYS choose a mounting location that is sufficiently strong to withstand the maximum pulling capacity of your winch.

Templates are not to scale.

WARNING

HW8000 & HW12000 DIMENSIONS

WARNING

Figure 2 - Template

7


HW15000 DIMENSIONS

HW8000 & HW12000 FOOTPRINT

HW15000 FOOTPRINT

Figure 3 - Template

8


1.2.1 Winch and fairlead Mounting

1.Yourmountingsurfacemustbeequaltoorgreaterthanthefootprintofthewinchframe.2.Makesurethemotor,drumandgearboxhousingarealignedcorrectly.

ALWAYS position fairlead with warning readily visible on top.

WARNING

1.Makesurethewinchisalignedcorrectly2.Setwinchinmountinglocation.Confirmrequiredboltlength.3.InstallboltsandtightentotorquespecifiedinTable4onPage9.

1.3 Install the Winch

Figure 4

9

1.3.1 Install the Winch fairlead


Table 4 - Mounting Torque Requirements

Powered Winches

HW8000 HW12000 HW15000

Winch Mounting Bolt Size

1/2”–13pitch8.8grade8 Required



Fairlead Mounting Bolt Size

M8x1.5pitch8.8grade2 Required



Winch Mounting Bolt Torque

119ft./lbs.161N-m

119ft./lbs.161N-m

169ft./lbs.229N-m

Fairlead Mounting Bolt Torque

20ft./lbs.28N-m

20ft./lbs.28N-m

65ft./lbs.88N-m

1. Disconnectpowertothehydraulicpumpordisconnectthehydrauliclinestothewinch.2. PlacethecabletensionerontothewinchasshowninFig5.3. Installthefourbuttonheadcapscrewsandtorqueto20ft.-lbs.4. Installthelockwashersandnutsontothefourbuttonheadcapscrewswhichprotrudefromthe

backofthemountingplate.Torqueto20ft.-lbs.

1.4 Cable Tensioner Installation

Figure 5 - HW8000, HW12000, & HW15000 Cable Tensioner

Cable Tensioner

Button Head Cap Screw

Install cable tensioner prior to Installing rope.

NOTICE

10


Figure 7 - HW8000, HW12000, & HW15000 Installation Diagram

Uponcompletionofinstallation,checkwinchforproperoperation.1.6 System Check

Advantage:Professionalwinchsystemfor“working”applications,costeffective,extremelypowerful,reliable,lightweight,andvariablelinespeedforhighworkrate.

ALWAYS complete the winch installation and hook attachment before hooking up the hydraulic pump.

ALWAYS pre-stretch rope and re-spool under load before use. Tightly wound rope reduces chances of “binding”, which can damage the rope.

A minimum of five (5) wraps of steel wire rope around the drum is necessary to support the rated load.

ALWAYS spool the winch rope onto the drum in the direction specified by the drum rotation labels on the winch and/or in the documentation. This is required for the automatic brake to function properly.

1.5 Install the RopeWARNING

Roller fairleadTheuseof4waysrollerfairleadcanreducethecontactingfrictionbecausethefairleadrollerscontactwiththewirerope.Butthefairleaddoesnotinsurethewireropewillwindontothedruminanorderlymanner.Theproperfleetanglewithin±5°mustbemaintainedforthewireropetowindontothedruminanorderlymanner.Iftheproperfleetangleisnotmaintained,itcanresultindamagetothewinchandwirerope.

Cable TensionerThepurposeofcabletensionerdeviceistokeepthewireropetightonthedrumwhilethewinchisinfreespoolmodeorwhilethereisnoloadonthewirerope.

Figure 6

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Hydraulic Fluid• Thehydraulicfluidshouldbeahighgrade,petroleumbasedfluid,withrust,oxidationandwear

resistance.Fluidcleanlinessandoperatingviscosityarecriticaltowinchreliability,efficiencyandservicelift.

Hydraulic Pump• Tomaintainthemaximumperformance,thehydraulicpumpmustsupplythemaximumflowof

hydraulicfluidatthehydraulicpressurestatedinspecification.

Hydraulic Control Valve• Thecontrolvalvemusthaveafour-wayspringreturntoneutralfeature,whichprovidesforopen

flowfromthepressureportsofthewinchtothereservoirinneutralpositionofthecontrol(motorspool).

Hydraulic Pressure Relief• Thehydraulicsystemrequiresapressurereliefvalvesetattheoperatingpressured.• Failuretousethecorrectpressureandflowmayresultindamagetothewinch,propertyorpersonal

injury.

Hydraulic Reservoir• Thehydraulicreservoirhassufficientcapacitytoprovidegoodheatdissipationinordertoprevent

over-heatingofthehydraulicfluid.• Mustbefittedwithanoilfillerdevicecomprisingstrainerandfilterandadipstick.Thecapacityof

thetankshouldbeatleast60liters.

Over-Center Valve / Counterbalance Valve• Givesmoothlycontrolledwinchoutwhenunderloadandtoprovidefulldynamicbraking.Itmustbe

installedtoholdfullload.• ThePortAofover-centervalvemeanstheinletportofoilfromreservoirandthePortBmeaningthe

returnportofoiltoreservoir.• Over-centervalveisastandardaccessoryfortheHWserieswinch.

Hydraulic Hoses• Thefollowinghydraulichosesarerecommendedformaximumefficiencyofthehydraulicwinch.

Thebiggernominalborehose,thebetterwinchperformance.• Allhoselengthsarekepttoaminimumbecausepressureandflowlossisincreasedashoselength

increases.• Pressureandreturnlinesinexcessof3.5meter(11.5feetv)shouldbecompensatedwithanin-

creaseinnominalboresize.Motordrainlinepipeshallberatedat1/4”BSPN.B.Inletline . . . . . . . . . . . . . . . . . . . . . . . 11/4”–11/2”nominalbore(N.B.)fromreservoirtopumpReturnline . . . . . . . . . . . . . . . . . . . . . 1”(N.B.)fromcontroltoreservoirPressurehoses. . . . . . . . . . . . . . . . . . 1/2”(N.B.)fromcontrolvalvetoover-centervalve


1.6 System Check (Continued)

12

2.1 Spooling in under Load

NEVER exceed winch’s rated line pull. Power-in the winch rope evenly and tightly on the drum. This prevents the outer winch wraps from sinking into the inner wraps, binding and damaging the winch rope.

NEVER touch winch rope or hook while someone else is at the control switch or during winching operation.

WARNING

Donotshockloadthewinchwhenspooling.Avoidshockloadswhenspoolingbypulsingthecontrolswitchtotakeupwinchropeslack.Shockloadscanmomentarilyfarexceedthewinchandroperatings.

DO NOT power the hook into the fairlead. This could cause damage to the fairlead.

NOTICE

2.2 Stretching the Wire Rope

ALWAYS pre-stretch rope and re-spool under load before use. Tightly wound rope reduces chances of “binding”, which can damage the rope.NEVER operate winch with less than five (5) wraps of wire rope around the drum. Rope could come loose from the drum, as the rope attachment to the drum is not designed to hold a load.

Thegoalofstretchingyourwireropeistowrapittightlyonthewinchdrumsothatitcansupportad-ditionallayersofwire.Itcantakeupto1,000lbs.toproperlystretchlargediametercable.Thiscanbeaccomplishedwithavehiclesuppliedasdeadweighttostretchtherope.Thisisanexercisethatwillmakeyourwireropelastlonger,avoidtanglesandensureatightlywrappedwinch.Usecaretoevenlywrapeachlayertopreventdamagetotherope.

WARNING

ALWAYS use supplied hand saver cable strap whenever spooling winch rope in or out, during installation or operation to avoid injury to hands and fingers.

WARNING

Operation Instructions

2.3 Safe Working Conditions

NEVER work around the winch rope while under load.NEVER step over a winch rope while under load.

WARNING

WARNING

TheoperatorshouldALWAYSoperatethewinchfromasafepositionwhenpullingaload.Thesafeareasare:Perpendiculartothewinchrope.

Thesafepositionwillhelppreventthewireropefromstrikingtheoperatorifthewireropefailswhenunderload.

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2.4 Clutch Operation

NEVER engage or disengage clutch if winch is under load, winch rope is in tension or drum is moving.

To prevent damage, ALWAYS fully engage or fully disengage the clutch lever.

WARNING

Theclutchlever,locatedonthewinchhousingoppositethemotor,controlstheclutchposition.Whentheclutchisengaged,thegeartrainiscoupledtothewinchdrumandpowercanbetransferredfromthewinchmotor.


2.4.2 disengage Clutch for free-SpoolingLifttheclutchT-handleupandturnitat90°counter-clockwiserotationtothe“Disengaged”position,ropecannowfree-spooloffthedrum.Figure8.

2.4.3 engage Clutch for WinchingToengage,lifttheclutchT-handleupandturnit90°clockwisetothe“Engaged”position.Neverengagetheclutchwhilethedrumisrotating.Figure9.

Figure 8 - Disengage Clutch

Figure 9 - Engage Clutch

Disengaged

To engage,lift and turn

2.4.1 drum drag BoltThedragissetbythefactory.Intime,thedragmayneedadjusting.Adjustthedragtocontrolfree-wheelingofthewinchdrum.Tomaintainatightdrum(resistsdrumrotation)turnthenylonboltbyquarterturnincrements.Thedrumshouldbetightenoughtoresistrotationandlooseenoughtoallowcabletobefreewheeledoffofthedrumforuse.Tightenthejamnutto6ft./lbs.

CAUTION

NEVER engage the clutch while the drum is rotating.

14

2.5.2 Recovery damperArecoverydamperisasafetydevicedesignedtohelpreducethepossibilityofinjuryorpropertydamageintheeventofawireropefailure.Placeinthemiddlethirdofaliverope.Figure11.

2.5.3 Snatch BlockAnimportantaidtosuccessfulwinchingistheuseofsnatchblock,whichcanbeusedtoincreasethepullingpowerofawinchorchangethedirectionofapull.Awinchdoublelinedwithasnatchblockcreatesamechanicallever-agecuttingtheeffortrequiredbynearlyhalf.Theuseofonesnatchblockshowsanindirectpullwherethevehicleislimitedduetounsuitablegroundorobstruction.Thepullontheloadistheactuallinepullofthewinch.Ifmorethanonesnatchblockisused,theymustbelocatedatleast40”(100cm)apart.Figure12.

Figure 11 - Recovery Damper

Figure 12 - Snatch Block

SnatchBlock


ThePower-Outfunctiondrivesthewinchmotoragainstthebrakewhichissimilartodrivingyourvehiclewiththeparkingbrakeengaged.DonotusethePower-Outfunctionforloweringaload--winchesarenotdesignedtobeusedashoists.Usethefree-spoolfunctiontopayoutwirerope.IfyouPower-Outover25feet,letthewinchcoolfor15minutes.

Do not use the winch as a lifting device or a hoist for vertical lifting.

WARNING

The Power-Out function should be used for relieving tension on the rope, not for extended distances.

CAUTION

2.5.1 Calculating fleet angleToobtainthebestwire/syntheticropeservice,thedirectionofpullwillbeonahorizontalwithin±15degreesandperpendiculartothecenterlineofthewinchdrumwithin±5degrees.Howeverwithoutmaintainingtheproperfleetangle;theropewillpileontoonesideoftheropedrumandpossiblydodamagetotheropeorwinch.Re-spoolyourwinchasrequired.

2.5 Winching Principles Figure 10 - Fleet Angle

RollerFairlead

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Maintenance

3.1 Wire Rope Replacement 1. DisengagetheclutchT-handle.2. Un-spooltheentirerope,andremoveitfromthedrum.3. Placethereplacementropethroughtherollerfairleadopening,passunderthedrumandinsertitinto

theholeonthedrumcore.Tightentheset-screwdownwardstosecurethewirerope.4. Aminimumoffive(5)wrapsofwireropearoundthedrumisnecessarytosupporttheratedload.

Figure 13 - Wire Rope Replacement

EngagedLift and turn to disengage

• Check the wire rope. Beforewinching,makesuretheropeiswoundonthedrumevenly.Ifthereismixedwinding,itisessentialtorewinditevenly.

• Becarefultokeeptheropeundertension.Neverguideawireropeontothedrumwithyourhand,useahandsavercablestrap.

3.2 Brake adjustment Undernormaluse,thebrakemechanismshouldnotrequireanyadjustment.Ifthebrakefailstoholdaload,thebrakediscmaybewornandrequireadjustmentorreplacement.Whenthebrakewearstothepointthattheloadbeginstoslip,thebrakecanbeadjustedasfollows:1. Loosentheboltonthebrakecoverandtakeouttheretainingrings2. Insertspacers/washerstomaintainthebrakespacerbetweentobe2.2±0.25mm3. Makesuretheclutchbaseplateisrotatedcounter-clockwiseby150–180degree

Figure 15 - Brake Adjustment

Figure 14 - Mixed Winding

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Maintenance

3.3 Lubrication Allmovingpartsinthewincharepermanentlylubricatedatthetimeofassembly.Undernormalcon-ditionsfactorylubricationwillsuffice.Ifre-lubricationofgearboxisnecessaryafterrepairordisas-semblyuseShellEP2orequivalentgrease.RegularlylubricateClutchT-handlewithlightoil.Neverlubricatethebrakesystem.

17

Troubleshooting

Table 5 - Troubleshooting

Symptom Possible Cause Remedy

Winch will notpull load

Motor may be damagedRemove and disassembly motor

and examine all parts and replace any that are worn or damaged

No oil supply to winch Check oil supply line connections and hoses

System not delivering full pressure to winch

Confirm pump is running to a high-er setting

Winch is Overload Reduce load to within rated capacity

The pressure is not adequate to power the load, or the back pres-

sure is too high

Check the pressure on each side of the hydraulic motor

Winch is mechanically binding up

Loosen, but not remove, the bolts that are attaching the tie bar and support racks. Rotate the drum, making sure that it turns freely

without sticking. Tighten the bolts.

The brake is not releasingThis requires disassembly of the

brake assembly. Remove and replace the brake assembly.

Winch will notpay out

Poor locking of 2nd stage ring gear Clean any burs left on the ring gear

The gear train is mechanically bundling up

This requires disassembly of the brake assembly. Remove and replace the brake assembly.

Winch is mechanically binding up Same as above

Damaged clutch T-handle linkage Replace or remove the clutch assembly

Oil leakage

Damaged drum seals Replace drum seal

Damaged drum flanges Replace drum

Front seal in the hydraulic motor shaft has failed Replace or repair the motor

Excessive noiseLow oil level Refill oil

Oil flow too high Check oil flow rate

Fail in immediate stop after power off

Fail in installing or damaged over- center valve Check over-center valve

Wrong oil flow direction of port A & B on the over-center valve Check over-center valve

Damaged brake assembly Replace or repair brake assembly

Drum noise

Insecure mounting Check mounting

Low oil flow Check flow rate

Low relief Check relief valve setting

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Checklist

Table 6 - Checklist

Before First

Operation

After EVERY

Use

Every 90 Days

Read, understand and follow the warnings and instructions in this manual. X

Check all fasteners and verify they are at the proper torque. Replace fasteners as needed. X X

If damaged, discontinue use and replace rope immediately. X X X

Keep winch, rope, and switch control free from contaminants. Use a clean rag or towel to remove any dirt and debris.

X

To prevent SERIOUS INJURY, DEATH and PROPERTY DAMAGE, you should read, understand and follow the warnings and instructions in this manual.

WARNING

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